Modular box assembly

ABSTRACT

A modular box assembly includes a box; a first thermal liner constructed of a first length of pre-laminated material, the pre-laminated material comprising an insulation batt in facing contact with a first sheet and with a second sheet, the first thermal liner defining three first liner panels; and a second thermal liner constructed of a second length of the pre-laminated material, the second thermal liner defining three second liner panels. A bottom box panel is covered by one of a first liner panel not covering any side box panel and a second liner panel not covering any side box panel. The insulation batt is formed from a mixture of reinforcement fibers and thermoplastic binder fibers, the reinforcement fibers comprising one of natural fibers, recycled cardboard, and a mixture of recycled cardboard and paper fibers.

REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 16/689,407, filed Nov. 20, 2019, which is a continuation of U.S. application Ser. No. 15/663,905, filed Jul. 31, 2017, now U.S. Pat. No. 10,551,110, and both of those applications are hereby specifically incorporated by reference herein in their entireties.

TECHNICAL FIELD

This disclosure relates to packaging. More specifically, this disclosure relates to a modular box assembly.

BACKGROUND

Packaging and shipping temperature sensitive contents can pose challenges. The contents can spoil, destabilize, freeze, melt, or evaporate during storage or shipping if the temperature of the contents is not maintained or the packaging is not protected from hot or cold environmental conditions. In applications such as hot food delivery, customers can be dissatisfied if the contents have cooled to ambient temperature upon delivery. Contents such as food, pharmaceuticals, electronics, or other temperature sensitive items can be damaged if exposed to temperature extremes. Many insulated packages are bulky and difficult to store prior to use. Additionally, many insulated packages are specialized to ship or carry hot goods, chilled goods, or frozen goods, and shippers must maintain large stocks of specialized packaging for each application. Additionally, many insulated packages cannot be recycled and are often disposed of in landfills.

SUMMARY

It is to be understood that this summary is not an extensive overview of the disclosure. This summary is exemplary and not restrictive, and it is intended to neither identify key or critical elements of the disclosure nor delineate the scope thereof. The sole purpose of this summary is to explain and exemplify certain concepts of the disclosure as an introduction to the following complete and extensive detailed description.

Disclosed is a modular box assembly comprising a box, the box comprising a bottom box panel and four side box panels, the four side box panels and the bottom box panel defining a box cavity; a first thermal liner positioned within the box cavity, the first thermal liner comprising a first length of pre-laminated material, the pre-laminated material comprising an insulation batt in facing contact with a first sheet and with a second sheet, the first thermal liner defining three first liner panels, wherein at least one side box panel is covered by a first liner panel; and a second thermal liner positioned within the box cavity, the second thermal liner comprising a second length of the pre-laminated material, the second thermal liner defining three second liner panels, wherein at least one other of the side box panels is covered by a second liner panel; wherein the bottom box panel is covered by one of a first liner panel not covering any side box panel and a second liner panel not covering any side box panel; and wherein the insulation batt is formed from a mixture of reinforcement fibers and thermoplastic binder fibers, the reinforcement fibers comprising one of natural fibers, recycled cardboard, and a mixture of recycled cardboard and paper fibers.

Also disclosed is a method of manufacturing a modular box assembly, comprising the steps of constructing an insulation batt by combining thermoplastic binder fibers and reinforcement fibers to result in a fibrous web, heating the textile batt to a temperature exceeding a glass transition temperature of the thermoplastic binder fibers, resulting in melting of the thermoplastic binder fibers, and cooling the fibrous web, the cooling causing the binder fibers to solidify and to couple reinforcement fibers together; constructing pre-laminated material by attaching a first sheet in facing contact with the insulation batt, and attaching a second sheet in facing contact with the insulation batt opposite the first sheet; cutting the pre-laminated material to size to define a first laminated member; cutting the pre-laminated material to size to define a second laminated member; folding portions of the first laminated member to form a first thermal liner; folding portions of the second laminated member to form a second thermal liner; positioning the first thermal liner in a box cavity defined by a box; and positioning the second thermal liner in the box cavity such that the first thermal liner and the second thermal liner together form an insulated cavity within the box cavity.

Various implementations described in the present disclosure may include additional systems, methods, features, and advantages, which may not necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims. The features and advantages of such implementations may be realized and obtained by means of the systems, methods, features particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. The drawings are not necessarily drawn to scale. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity.

FIG. 1 is a perspective view of a modular box assembly comprising an insulated box, a box top, and a carrying accessory in accordance with one aspect of the current disclosure.

FIG. 2 is a perspective view of the modular box assembly of FIG. 1 with the insulated box of FIG. 1 in an open position.

FIG. 3 is a cross-section of the insulated box of FIG. 1 taken along line 3-3 shown in FIG. 2.

FIG. 4 is a cross-section of the modular box assembly of FIG. 1 taken along line 4-4 shown in FIG. 2.

FIG. 5 is a perspective view of a method for manufacturing an insulated panel in accordance with another aspect of the current disclosure.

FIG. 6A is a perspective view of another aspect of an insulated panel in accordance with another aspect of the current disclosure prepared for installation on the insulated box of FIG. 1.

FIG. 6B is a perspective view of the insulated panel of FIG. 6A partially installed on the insulated box of FIG. 1.

FIG. 6C is a perspective view of the insulated panel of FIG. 6A completely installed on the insulated box of FIG. 1.

FIG. 7 is a top view of a box blank of the insulated box of FIG. 1 without insulated panels.

FIG. 8 is a perspective view of the insulated box of FIG. 1 in a collapsed configuration.

FIG. 9 is a top view of the carrying accessory of the modular box assembly of FIG. 1.

FIG. 10 is a perspective view of the modular box assembly comprising the insulated box of FIG. 1 and another aspect of a box top in accordance with another aspect of the present disclosure.

FIG. 11 is a perspective view of the modular box assembly comprising the insulated box of FIG. 1 and another aspect of a box top in accordance with another aspect of the present disclosure.

FIG. 12 is a perspective view of the modular box assembly comprising the insulated box of FIG. 1 and another aspect of a box top in accordance with another aspect of the present disclosure.

FIG. 13 is a top view of a handle top in accordance with another aspect of the present disclosure.

FIG. 14 is a perspective view of another aspect of the modular box assembly in accordance with another aspect of the present disclosure comprising the box of the insulated box of FIG. 1 and the handle top of FIG. 13.

FIG. 15 is a perspective view of an inner box in accordance with one aspect of the present disclosure.

FIG. 16 is a top view of an inner box blank of the inner box of FIG. 15.

FIG. 17 is a perspective view of another aspect of the insulated box in accordance with another aspect of the present disclosure.

FIG. 18 is a perspective view of an outer sleeve of the modular box assembly in accordance with another aspect of the present disclosure.

FIG. 19 is a perspective view of a support bracket of the modular box assembly in accordance with another aspect of the present disclosure.

FIG. 20 is a downward cross-section of another aspect of the modular box assembly comprising the inner box of FIG. 15, the insulated box of FIG. 17, and the outer sleeve of FIG. 18 in accordance with another aspect of the present disclosure.

FIG. 21 is a side cross-section of the modular box assembly of FIG. 20, further comprising the handle top of FIG. 11 and a bottom insulated panel in accordance with another aspect of the present disclosure.

FIG. 22 is a side cross-section of another aspect of the modular box assembly comprising the insulated box of FIG. 17, the outer sleeve of FIG. 18, the support bracket of FIG. 19, a divider panel, and temperature maintaining packs in accordance with another aspect of the present disclosure.

FIG. 23 is an exploded perspective view of another aspect of the insulated box in accordance with another aspect of the present disclosure.

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and the previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, and, as such, can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The following description is provided as an enabling teaching of the present devices, systems, and/or methods in its best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the present devices, systems, and/or methods described herein, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an element” can include two or more such elements unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

For purposes of the current disclosure, a material property or dimension measuring about X or substantially X on a particular measurement scale measures within a range between X plus an industry-standard upper tolerance for the specified measurement and X minus an industry-standard lower tolerance for the specified measurement. Because tolerances can vary between different materials, processes and between different models, the tolerance for a particular measurement of a particular component can fall within a range of tolerances.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

The word “or” as used herein means any one member of a particular list and also includes any combination of members of that list. Further, one should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain aspects include, while other aspects do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular aspects or that one or more particular aspects necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular aspect.

Disclosed are components that can be used to perform the disclosed methods and systems. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutation of these may not be explicitly disclosed, each is specifically contemplated and described herein, for all methods and systems. This applies to all aspects of this application including, but not limited to, steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the disclosed methods.

Disclosed is a modular box assembly and associated methods, systems, devices, and various apparatus. The modular box assembly comprises a box, a box top, and a carrying accessory. It would be understood by one of skill in the art that the disclosed modular box assembly is described in but a few exemplary embodiments among many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom.

FIG. 1 is a perspective view of a modular box assembly 100 in a closed position in accordance with one aspect of the present disclosure. The modular box assembly 100 can comprise a box 101 and a variety of accessories configured to adapt the box 101 for different applications, such as shipping hot goods, chilled goods, frozen goods, or goods at ambient temperature. FIGS. 1-23 depict these accessories as well as several different exemplary configurations for the box 101.

In the present aspect, the modular box assembly 100 can comprise the box 101, a carrying accessory 170, and a box top 190. The box 101 can be configured as one aspect of an insulated box 110 comprising a plurality of insulated panels 130 a-d (insulated panels 130 c,d shown in FIG. 3). The box 101 can comprise a rigid board material such as corrugated cardboard; however in other aspects, the box 101 can comprise other suitable rigid board materials, such as wood, plastic, metal, or any other material. The insulated box 110 can be configured to transport hot, chilled, or frozen goods, and the insulated panels 130 a-d can maintain a desired temperature within the insulated box 110. In other aspects, the box 101 can be configured as an uninsulated box, such as when goods are transported at ambient temperature.

The box 101 can comprise a first pair of opposing side panels 112 a,b and a second pair of opposing side panels 122 a,b. The side panels 112 a,b, 122 a,b can each be a rigid panel. The side panel 112 a can be substantially parallel to the side panel 112 b, and the side panel 122 a can be substantially parallel to the side panel 122 b. Each side panel 112 a,b can be substantially perpendicular to both side panels 122 a,b. The box 101 can define a rectangular or square cross-sectional shape; however, in other aspects, the box 101 can define a different cross-sectional shape such as a circular, triangular, pentagonal, or hexagonal, shape or any other desired shape.

The box 101 can define a top end 102 and a bottom end 104, and the top end 102 can be disposed opposite from the bottom end 104. The side panels 112 a,b can define lips 114 a,b, respectively, disposed proximate to the top end 102 of the insulated box 110. The side panels 122 a,b can define lips 124 a,b, respectively, disposed proximate to the top end 102 of the insulated box 110. The box 101 can define a box opening 106 at the top end 102. The box top 190 can be sized and shaped to fit between the lips 114 a,b and the lips 124 a,b to cover the box opening 106 when the box 101 is in the closed position. The box top 190 can comprise an insulated panel 140 which can be substantially identical in construction to the insulated panels 130 a-d; however in other aspects, the insulated panel 140 can differ in construction from the insulated panels 130 a-d.

The insulated panels 130 a-d can be attached to the side panels 112 a,b, 122 a,b. The insulated panels 130 a,c (130 c shown in FIG. 3) can be respectively attached to the side panels 112 a,b, and the insulated panels 130 b,d (130 d shown in FIG. 3) can be respectively attached to the side panels 122 a,b. Each insulated panel 130 a-d can define a border 158 extending around the respective insulated panel 130 a-d. An area encircled by the border 158 can define an insulated portion 161 of the respective insulated panel 130.

The border 158 of each insulated panel 130 a-d can define a top seam 156 a and a bottom seam 156 b extending outwards from the insulated portion 161 of the respective insulated panel 130 a-d. The top seam 156 a can be attached to the adjacent side panel 112 a,b, 122 a,b of the box 101 proximate the top end 102 of the box 101. In the present aspect, the top seam 156 a of each insulated panel 130 a-d can attach to the lip 114 a,b, 124 a,b of the adjacent side panel 112 a,b, 122 a,b. The bottom seam 156 b of each insulated panel 130 a-d can be attached to the adjacent side panel 112 a,b, 122 a,b along the bottom end 104 of the box 101. The seams 156 a,b can be attached by an adhesive such as a glue, cement, epoxy, mastic, double-sided tape, cohesive, or any other suitable material, and the seams 156 a,b can secure the insulated panels 130 a-d to the respective adjacent side panels 112 a,b, 122 a,b.

The carrying accessory 170 can extend beneath the box 101 to facilitate hand carrying of the box 101. The carrying accessory 170 can define a U-shape. A middle portion 180 can extend beneath the box 101. A first side portion 172 a can extend upwards from the middle portion 180 and can be adjacent to the insulated panel 130 a. A second side portion 172 b can extend upwards from the middle portion 180 and can be adjacent to the insulated panel 130 c (shown in FIG. 3).

In the present aspect, the carrying accessory 170 can be attached to the box 101 or the insulated panels 130 a,c such as with an adhesive, such as a glue, cement, epoxy, mastic, double-sided tape, cohesive, or any other suitable material. In other aspects, the carrying accessory 170 can be mechanically attached, such as with a hook-and-loop fastener, stitching, or staples, and the mechanical attachment of the carrying accessory 170 can be configured to be selectively attached and detached from the box 101 such as with hook-and-loop fasteners. In other aspects, the carrying accessory 170 may not be attached to the box 101. In some aspects, the side portions 172 a,b can extend upwards adjacent to the insulated panels 130 b,d. In some aspects, the carrying accessory 170 can have four side portions (not shown), and one side portion can be positioned adjacent to each of the four insulated panels 130 a-d.

The side portions 172 a,b can respectively define handles 178 a,b. In the present aspect, handle 178 a can be attached to an end 174 a of the first side portion 172 a by a base strip 176 a. Handle 178 b can be attached to an end 174 b of the second side portion 172 b by a base strip 176 b. The handles 178 a,b can comprise twisted paper rope, and the handles 178 a,b can be laminated between two layers of the respective base strip 176 a,b. In other aspects, the handles 178 a,b can be integrally formed with the base strips 176 a,b, and the handles 178 a,b and the base strips 176 a,b can comprise a common material. For example, the base strips 176 a,b and the handles 178 a,b can comprise a heavy kraft paper, plastic, posterboard, cardboard, or other suitable material. In other aspects, the handles 178 a,b can comprise a fiber such as cotton, hemp, jute, or bamboo fiber.

The base strips 176 a,b can be attached to the respective ends 174 a,b with an adhesive such as a glue, cement, epoxy, mastic, double-sided tape, cohesive, or any other suitable material. The ends 174 a,b and the handles 178 a,b can extend upwards above the box opening 106. In other aspects, the handles 178 a,b and the ends 174 a,b may not extend above the box opening 106, and the handles 178 a,b can be positioned adjacent to the insulated panels 130 b,d. In other aspects, the handles 178 a,b can have a different shape and can be attached directly to the respective side portions 172 a,b. In some aspects, the handles 178 a,b can be formed integrally with the respective side portions 172 a,b, for example, by cutting a hand hole through the respective side portion 172 a,b.

FIG. 2 is a perspective view of the modular box assembly 100 of FIG. 1 with the box top 190 in an open position. In the open position, the box top 190 can be removed from the box opening 106, thereby exposing a box cavity 206 defined within the box 101. The first pair of opposing side panels 112 a,b and the second pair of opposing side panels 122 a,b of the box 101 can define the box cavity 206. A pair of shoulders 222 a,b can extend inwards into the box cavity 206 from each of the side panels 122 a,b, as represented by the shoulder 222 b (shoulder 222 a shown in FIG. 3). The shoulders 222 a,b are configured to support the box top 190 when the box top 190 is positioned between the lips 114 a,b, 124 a,b in the closed position. In the closed position, the box top 190 can cover the box opening 106 and enclose the box cavity 206.

In the present, aspect, the box top 190 can comprise the insulated panel 140 and a top panel 240. The top panel 240 can be a rigid panel. The insulated panel 140 can be attached to the top panel 240 and positioned atop the top panel 240 as shown. In other aspects, the box top 190 can be flipped, and the insulated panel 140 can be positioned beneath the top panel 240. In other aspects, the box top 190 can comprise a second insulated panel (not shown), and the box top 190 can be insulated on both sides for added insulation value. In other aspects, the box top 190 may not comprise the insulated panel 140, and the top panel 240 can be uninsulated. The top panel 240 can comprise corrugated cardboard in the present aspect; however, in other aspects the top panel 240 can be comprise a suitable rigid board material such as wood, plastic, metal, or any other material.

FIG. 3 is a cross-section of the insulated box 110 of FIG. 1 taken along line 3-3 shown in FIG. 2, with the carrying accessory 170 and the box top 190 removed. As shown, each shoulder 222 a,b can comprise two sub-shoulders 322. The shoulder 222 a can comprise the sub-shoulders 322 a,b, and the shoulder 222 b can comprise the sub-shoulders 322 c,d. The sub-shoulders 322 a-d can be defined by a plurality of first wings 312 a-d and a plurality of second wings 324 a-d. The first wings 312 a,b can be attached at opposite sides of the side panel 112 a, and the first wings 312 c,d can be attached at opposite sides of the side panel 112 b. The second wings 324 a,b can be attached at opposite sides of the side panel 122 a, and the second wings 324 c,d can be attached at opposite sides of the side panel 122 b.

The second wing 324 a can be folded inwards at a hinge 365 a and positioned adjacent to an inner side surface 326 a defined by the side panel 122 a, and the first wing 312 c can be folded at a hinge 370 c and positioned adjacent to the second wing 324 a. The second wing 324 a and the first wing 312 c can be secured in position, such as with an adhesive, to form the sub-shoulder 322 a. The second wing 324 b can be folded inwards at a hinge 365 b and positioned adjacent to the inner side surface 326 a, and the first wing 312 a can be folded at a hinge 370 a and positioned adjacent to the second wing 324 b. The second wing 324 b and the first wing 312 a can be secured in position, such as with an adhesive, to form the sub-shoulder 322 b.

For the sub-shoulder 322 c of shoulder 222 b, the second wing 324 c can be folded inward at a hinge 365 c and positioned adjacent to an inner side surface 326 b defined by the side panel 122 b. The first wing 312 d can then be folded at a hinge 370 d and positioned adjacent to the second wing 324 c. The first wing 312 d and the second wing 324 c can be secured in position, such as with an adhesive, to form the sub-shoulder 322 c. For the sub-shoulder 322 d of shoulder 222 b, the second wing 324 d can be folded inward at a hinge 365 d and positioned adjacent to the inner side surface 326 b. The first wing 312 b can then be folded at a hinge 370 b and positioned adjacent to the second wing 324 d. The first wing 312 b and the second wing 324 d can be secured in position, such as with an adhesive, to form the sub-shoulder 322 d.

The formation of the sub-shoulders 322 a-d can also secure each side panel 112 a,b to each side panel 122 a,b, thereby defining the square or rectangular horizontal cross-section of the box 101. The box 101 can further comprise a bottom panel 306. The bottom panel 306 can be a rigid panel. The bottom panel 306 can be disposed at the bottom end 104 of the box 101, and the bottom panel 306 can be attached to each of the side panels 112 a,b, 122 a,b. The bottom panel 306 can further define the box cavity 206. The box 101 is but one example of a box, and the methods discussed below for insulating the box 101 to form the insulated box 110 can be applied to a box of another shape, size, or form.

In the present aspect, the bottom panel 306 can define a center subpanel 380 disposed at a center of the bottom panel 306. The center subpanel 380 can be substantially rectangular in shape. A center fold line 382 can extend between the center subpanel 380 and each side panel 112 a,b, and the center fold line 382 can substantially bisect the bottom panel 306, with the exception of within the center subpanel 380. The center fold line 382 can also bisect each side panel 112 a,b, as shown and further described with respect to FIG. 7. Four corner fold lines 384 a-d can extend between the corners of the center subpanel 380 and the hinges 370 a-d. The corner fold line 384 a can extend from the hinge 370 a to the center subpanel 380. The corner fold line 384 b can extend from the hinge 370 b to the center subpanel 380. The corner fold line 384 c can extend from the hinge 370 c to the center subpanel 380. The corner fold line 384 d can extend from the hinge 370 d to the center subpanel 380.

A plurality of V-shaped fold lines 386 a-f can extend between the hinges 370 a-d and the center fold line 382. The V-shaped fold lines 386 a-c can each extend from the hinge 370 a to center fold line 382 and then to the hinge 370 b. The V-shaped fold lines 386 a-c can be defined between the corner fold lines 384 a and 384 b. The V-shaped fold lines 386 d-f can each extend from the hinge 370 c to center fold line 382 and then to the hinge 370 d. The V-shaped fold lines 386 d-f can be defined between the corner fold lines 384 c and 384 d. The center subpanel 380, the center fold line 382, the corner fold lines 384 a-d, and the V-shaped fold lines 386 a-f can cooperate to collapse the insulated box 110 and to provide the bottom panel 306 with a truncated pyramidal shape when collapsed, as further discussed below with respect to FIG. 8.

The box 101 of the insulated box 110 can be clad with the insulated panels 130 a-d. The insulated panel 130 a can be attached to an outer side surface 328 a defined by the side panel 122 a. The insulated panel 130 b can be attached to an outer side surface 314 a defined by the side panel 112 a. The insulated panel 130 c can be attached to an outer side surface 328 b defined by the side panel 122 b. The insulated panel 130 d can be attached to an outer side surface 314 b defined by the side panel 112 b. In the present aspect, the box 101 can be externally clad with the insulated panels 130 a-d, however in other aspects, the box 101 can be internally clad, both internally and externally clad, or a mixed arrangement of partially internally clad and partially externally clad with insulated panels 130.

In the present aspect, each insulated panel 130 a-d can comprise an insulation batt 350, a first sheet 352, and a second sheet 354. The insulation batt 350 can be encapsulated in a panel cavity 351 defined between the first sheet 352 and the second sheet 354. The insulation batt 350 can be encapsulated by the border 158 which can extend around a perimeter 359 of the insulation batt 350, thereby sealing the panel cavity 351. The panel cavity 351 containing the insulation batt 350 can define the insulated portion 161 of the respective insulated panel 130 a-d. The border 158 can be a seam formed by attaching a perimeter portion of the first sheet 352 which overhangs the perimeter 359 of the insulation batt 350 with a perimeter portion of the second sheet 354 which also overhangs the perimeter 359 of the insulation batt 350. The first sheet 352 can be attached to the second sheet 354 with an adhesive such as a glue, cement, epoxy, mastic, cohesive, double-side tape or other suitable adhesive to form the border 158. In some aspects, the border 158 can be formed by mechanically fastening the first sheet 352 to the second sheet 354, such as by stapling, stitching, or any other suitable method of fastening.

The border 158 can further define a first side seam 356 a and a second side seam 356 b. In the present aspect, the first side seam 356 a and the second side seam 356 b can be vertically oriented seams. The first side seam 356 a and the second side seam 356 b of the border 158 can be folded inwards and disposed between the insulation batt 350 of the insulated portion 161 and the outer side surface 328 a,b of the respective side panels 122 a,b or the outer side surfaces 314 a,b of the respective side panels 112 a,b. The first side seam 356 a and the second side seam 356 b can be attached to the adjacent side panel 112 a,b, 122 a,b, thereby further securing the insulated panel 130 a-d to the adjacent side panel 112 a,b, 122 a,b and enclosing the insulation batt 350 between the first sheet 352 and the adjacent side panel 112 a,b, 122 a,b. By folding the first side seam 356 a and the second side seam 356 b inwards, the insulation batt 350 and the insulated portion 161 can extend completely across or nearly completely across the width of the adjacent side panel 112 a,b, 122 a,b without leaving the first side seam 356 a and the second side seam 356 b sticking outwards beyond the side panel 112 a,b, 122 a,b. This configuration can provide full insulation or nearly full insulation over the width of the adjacent side panel 112 a,b, 122 a,b.

With the first side seam 356 a and the second side seam 356 b folded inwards, the first sheet 352 can be attached to the respective adjacent side panel 112 a,b, 122 a,b with an adhesive such as a glue, cement, epoxy, mastic, double-sided tape, cohesive, or other suitable material. A portion of the second sheet 354 extending between the first side seam 356 a and the second side seam 356 b can also be in facing contact with the adjacent side panel 112 a,b, 122 a,b and can optionally be attached with the adhesive. In other aspects, the insulated panels 130 a-d may not comprise the second sheet 354, and either the insulation batt 350 can be in facing contact with the respective adjacent side panel 112 a,b, 122 a,b, or the first sheet 352 can fully encapsulate the insulation batt 350.

FIG. 4 is a cross-section of the modular box assembly 100 of FIG. 1 taken along line 4-4 shown in FIG. 2. In the present view, the carrying accessory 170 has been removed. The modular box assembly 100 can further comprise an insulated cavity panel 430 which can be disposed within the box cavity 206. The insulated cavity panel 430 can be constructed similar to the insulated panels 130 a-d, 190; however, in the present aspect, the insulated cavity panel 430 can be a loose panel. The insulated portion 161 of the insulated cavity panel 430 can be shaped and sized complimentary to the horizontal cross-section of the box 101 in order to provide a close fit within the box cavity 206.

As shown, the insulated cavity panel 430 can divide the box cavity 206 into a first sub-compartment 406 a and a second sub-compartment 406 b. In the present aspect, the insulated cavity panel 430 can be horizontally oriented, and the first sub-compartment 406 a can be an upper sub-compartment while the second sub-compartment 406 b can be a lower sub-compartment. In other aspects, the insulated cavity panel 430 can be vertically oriented to divide the box cavity 206 into side-by-side compartments. In some aspects, the insulated box 110 can comprise multiple cavity panels 430 disposed within the box cavity 206 to divide the box cavity 206 into more than two compartments or no insulated cavity panels 430 so that the box cavity 206 is a single compartment. Dividing the box cavity 206 into sub-compartments can be desirable in order to package both hot and cold contents in the same insulated box 110 or other contents that should be stored at different temperatures.

In the present aspect, the bottom panel 306 can be uninsulated. Optionally, the insulated cavity panel 430 can be placed atop the bottom panel 306 to provide insulation for the bottom end 104 of the insulated box 110. In other aspects, the insulated box 110 can further comprise another insulated panel 130 (not shown) attached internally or externally to the bottom panel 306. In aspects in which the box top 190 can be uninsulated, the insulated cavity panel 430 can be positioned adjacent to the box top 190 to provide insulation for the top end 102 of the insulated box 110. In some aspects, the bottom panel 306 can be insulated and the insulated cavity panel 430 can be placed atop the bottom panel 306 in order to provide additional insulation for example. In some aspects, the modular box assembly 100 can comprise multiple insulated cavity panels 430 positioned within the box cavity 206. In other aspects, the modular box assembly 100 can comprise any or all of the insulated cavity panel 430, a bottom insulated panel 2130 (shown in FIG. 21), and a divider panel 2230 (shown in FIG. 22).

The bottom seam 156 b and the top seam 156 a of the border 158 of each insulated panel 130 a-d can extend outwards from the perimeter 359 of the insulation batt 350 and the insulated portion 161. As previously discussed, the bottom seams 156 b and the top seams 156 a can be attached to the respective adjacent side panel 112 a,b, 122 a,b with the adhesive in order to secure the insulated panels 130 a-d, to the box 101 proximate the top end 102 and the bottom end 104. In such aspects, the second sheet 354 can be attached to the adjacent side panel 112 a,b, 122 a,b, and the first sheet 352 may not contact the adjacent side panel 112 a,b, 122 a,b at the bottom seam 156 b and the top seam 156 a; however, the insulation batt 350 remains enclosed between the first sheet 352 and the adjacent side panel 112 a,b, 122 a,b. Optionally, portions of the second sheet 354 disposed between the top seams 156 a and the bottom seam 156 b can also be attached to the respective adjacent side panel 112 a,b, 122 a,b with the adhesive.

The outward extending top seams 156 a can leave the lips 114 a,b, 124 a,b uninsulated; however, because the box top 190 rests below the box opening 106 on the shoulders 222 a,b (should 222 b shown in FIG. 3), the top end 102 of the insulated box 110 can remain fully insulated. Similarly, the bottom seams 156 b can leave a portion of the side panels 112 a,b, 122 a,b proximate the bottom panel 306 uninsulated. However, in aspects in which the insulated cavity panel 430 can be positioned atop the bottom panel 306, the insulated cavity panel 430 can fully insulate the bottom end 104 of the insulated box 110. In other aspects, either or both of the bottom seams 156 b and top seams 156 a can be folded inward towards the insulation batt 350 and the insulated portion 161, and the insulation batt 350 can fully cover the height of the side panels 112 a,b, 122 a,b.

The outwardly extended bottom seams 156 b can define a bottom taper 458 extending around the insulated box 110 proximate the bottom end 104. The bottom taper 458 can cooperate with the lips 114 a,b, 124 a,b to securely stack multiple insulated boxes 110 on top of one another. The lips 114 a,b, 124 a,b of a lower insulated box of the stack of insulated boxes can deflect outwards allowing the bottom taper 458 of an upper insulated box to nest between the lips 114 a,b, 124 a,b and atop the box top 190 of the lower insulated box. By nesting between the lips 114 a,b, 124 a,b, the lips 114 a,b, 124 a,b can prevent the upper insulated box from sliding sideways off the top end 102 of the lower insulated box. The insulated boxes 110 can also be conveyable, such as on a conveyor belt, and the insulated boxes 110 can be rigid and strong enough to resist collapse on the conveyor belt. In other aspects, the lips 114 a,b, 124 a,b can be configured to be flush with the top panel 240 of the box top 190 when the box top 190 is in the closed position.

FIG. 5 is a perspective view of a method of manufacturing for an insulated panel 510. The method can apply to the manufacture of the insulated panels 130 a-d,140,430 or an insulation wrap 1730 (shown in FIG. 17). In a step 501, the insulation batt 350 can be positioned between the first sheet 352 and the second sheet 354. The first sheet 352 and the second sheet 354 can be sized and shaped complimentary to each other; however in some aspects, the sheets 352,354 can differ in size and shape. The insulation batt 350 and the sheets 352,354 can each be flat and substantially planar before assembly. In the present aspect, the insulation batt 350 can be approximately ⅜″ thick; however this thickness is not limiting. The thickness can range from 1/16″ to over 2″ with a preferred range of ¼″ to ½″. Also, as disclosed in at least one of the provisional applications incorporated by reference below, each batt used within the modular box assembly 100 may be of equal thickness, or may be of unequal thicknesses. A starting batt may be split longitudinally to provide two, three, or more partial thickness batts.

The first sheet 352 can define a first outer edge 552, and a portion of the first sheet 352 proximate the first outer edge 552 can define a first perimeter portion 542. The second sheet 354 can define a second outer edge 554, and a portion of the second sheet 354 proximate the second outer edge 554 can define a second perimeter portion 544. The sheets 352,354 can be sized to overhang the insulation batt 350 on all sides with the first perimeter portion 542 and the second perimeter portion 544 extending beyond the perimeter 359 of the insulation batt 350. The first perimeter portion 542 can encompass a first interior portion 536 of the first sheet 352, and the second perimeter portion 544 can encompass a second interior portion 538 of the second sheet 354. The interior portions 536,538 can be sized and shaped complimentary to the insulation batt 350.

Surfaces of the sheets 352,354 facing one another can be treated with an adhesive 530 such as a cohesive. In various aspects, the adhesive can be a glue, epoxy, cement, double-sided tape, or other suitable adhesive. The surfaces can be entirely treated with the adhesive 530 or selectively treated with the adhesive 530. In the aspect shown, the perimeter portions 542,544 can be selectively treated with the adhesive 530. In some aspects, the insulation batt 350 can also be adhered to the interior portions 536,538 of the sheets 352,354.

In a step 502, the sheets 352,354 can be aligned and positioned in facing engagement wherein the first perimeter portion 542 can be attached to the second perimeter portion 544 by the adhesive 530. The insulation batt 350 can be aligned between the interior portions 536,538. Attaching the perimeter portions 542,544 can form the border 158 of the insulated panel 510 around the perimeter 359 of the insulation batt 350. As depicted in step 502, the bottom seam 156 b has been formed, the first side seam 356 a and the second side seam 356 b are partially formed, and the top seam 156 a is yet to be formed.

The border 158 can seal the insulation batt 350 within the panel cavity 351 defined between the interior portions 536,538 of the sheets 352,354, respectively. Portions of the insulated panel 510 containing the insulation batt 350 can define the insulated portion 161 of the insulated panel 510. In some aspects, the insulation batt 350 can be aligned off-center from the sheets 352,354 wherein the border 158 can extend outwards further in some areas than others. In some aspects, the first side seam 356 a, the second side seam 356 b, the bottom seam 156 b, and the top seam 156 a can define different widths from one another. For example and without limitation, the first side seam 356 a can extend outwards from the insulation batt 350 further than the bottom seam 156 b or vice versa.

In a step 503, the first perimeter portion 542 has been fully attached to the second perimeter portion 544, thereby forming the completed border 158. Each of the first side seam 356 a, the second side seam 356 b, the bottom seam 156 b, and the top seam 156 a are fully formed. Manufacturing of the insulated panel 510 is thus completed; however in some aspects, the method can comprise additional steps such as cutting slots into the border 158. The border 158 can fully encapsulate the insulation batt 350 within the panel cavity 351; however in some aspects, the insulation batt 350 may not be fully encapsulated. In some aspects, the insulation batt 350 can define a complex shape which can comprise curves, notches, cutouts, or other features which can be reflected by complimentary shapes of the border 158 and the insulated portion 161.

In other aspects, the border 158 may not fully encompass and encapsulate the insulation batt 350. In some aspects, some portions of the perimeter 359 may be exposed at an unfinished side or a cutout of the border 158. In some aspects, the insulated panel 510 may not define the border 158 on any portion of the perimeter of the insulated panel 510, and the entire perimeter can define an unfinished edge. In such aspects, the insulated panel 510 can comprise pre-laminated paper and each of the sheets 352,354 can be attached in facing contact with the insulation batt 350 with, for example and without limitation, an adhesive. In some aspects in which the insulated panel 510 defines the border 158, the insulation batt 350 can also be attached in facing contact with one or both of the sheets 352,354. In some aspects, the pre-laminated paper can be provided in a roll, and the insulated panels 510 can be cut to size from the roll. In other aspects, the first sheet 352 and the second sheet 354 can be halves of a single sheet (not shown) which can be folded substantially in half. In such aspects, the insulation batt 350 can be encapsulated between the two halves of the single sheet. In other aspects, the second sheet 354 can be a board (not shown), such as a piece of cardboard, and the insulation batt 350 can be encapsulated between the first sheet 352 and the board.

In some aspects, the second sheet 354 can be a board 2154 (shown in FIG. 21). In such applications, the board 2154 can be rigid and the first sheet 352 can laminate and encapsulate the insulation batt 350 to the board 2154 to provide a rigid insulated panel, such as the bottom insulated panel 2130.

FIGS. 6A-C show perspective views of a method for attaching the insulated panel 130 a to the side panel 122 a. In FIG. 6A, the insulated panel 130 a is shown partially attached to the side panel 122 a. In the present aspect, the insulated panel 130 a and the adjacent insulated panel 130 b can be separate and isolated insulation panels 130 which are not connected together. By using separate insulated panels 130, manufacturing stress around corners of the insulated box 110 can be reduced during assembly of the insulated box 110, thereby reducing the likelihood of ripping or tearing the insulated panels 130 during assembly. The insulated panel 130 a can be positioned adjacent to the side panel 122 a, and the bottom seam 156 b can be attached to a perimeter area 656 of the outer side surface 328 a. The perimeter area 656 can extend around the edges of the side panel 122 a. Specifically, the bottom seam 156 b can be attached to a bottom portion (not shown) of the perimeter area 656 extending along the bottom end 104 of the side panel 122 a. The perimeter area 656 can also define a first portion 658 a and a second portion 658 b extending upwards from the bottom portion towards a top portion 658 c. The top portion 658 c can extend along the lip 124 a proximate the top end 102 of the side panel 122 a.

The bottom seam 156 b of the border 158 can extend outwards from the insulated portion 161 of the insulated panel 130 a, and the second sheet 354 of the bottom seam 156 b can be attached to the outer side surface 328 a. In other aspects, the bottom seam 156 b can be folded inwards towards the insulation batt 350 (not shown) encapsulated within the insulated portion 161. The bottom seam 156 b can be attached in facing contact with the side panel 122 a by an adhesive such as a glue, epoxy, cement, mastic, or any other suitable adhesive. In other aspects, the bottom seam 156 b can be mechanically attached to the side panel 122 a such as with a hook-and-loop fastener, stitching, or staples, or other suitable fasteners. In the present aspect, the first side seam 356 a and the second side seam 356 b (shown in FIG. 6B) can be folded inwards towards the insulation batt 350 (not shown) encapsulated within the insulated portion 161. The first side seam 356 a can be attached to the bottom portion (not shown) at an intersection between the bottom portion and the first portion 658 a of the perimeter area 656. The second side seam 356 b can be attached to the bottom portion (not shown) at an intersection between the bottom portion and the second portion 658 b of the perimeter area 656.

In FIG. 6B, the insulated panel 130 a is shown with the bottom seam 156 b attached to the side panel 122 a, and the first side seam 356 a and the second side seam 356 b partially attached to the first portion 658 a and the second portion 658 b of the perimeter area 656, respectively. The first sheet 352 of the first side seam 356 a and the second side seam 356 b can be attached in facing contact to the perimeter portion 656 of the outer side surface 328 a by an adhesive such as a glue, epoxy, cement, mastic, double-sided tape, cohesive, or other suitable adhesive. In other aspects, the first sheet 352 of the first side seam 356 a and the second side seam 356 b can be mechanically attached to the perimeter portion 656 of the outer side surface 328 a, such as with a hook-and-loop fastener, stitching, or staples, or other suitable fasteners. In the aspect shown, the insulated panel 130 a is shown as first attached proximate the bottom end 104 and then subsequently attached upwards along the first side seam 356 a and the second side seam 356 b towards the top end 102; however, this sequence and direction of attachment are not limiting. The insulated panel 130 a can first be attached at the first side seam 356 a, the second side seam 356 b, or the top seam 156 a and further attached in a sideways or downwards direction, or in any other suitable sequence. In some aspects, the second sheet 354 of the insulated portion 161 can also be attached to the outer side surface 328 a by an adhesive such as a glue, epoxy, cement, mastic, or any other suitable adhesive.

FIG. 6C shows the insulated panel 130 a completely attached to the side panel 122 a. The first side seam 356 a (shown in FIG. 6B) can be completely attached to the first portion 658 a (shown in FIG. 6B) of the perimeter area 656 (shown in FIG. 6B) from the bottom end 104 to the top end 102. The second side seam 356 b (shown in FIG. 6B) can be completely attached to the second portion 658 b (shown in FIG. 6B) of the perimeter area 656 (shown in FIG. 6B) from the bottom end 104 to the top end 102. The top seam 156 a can be fully attached to the top portion 658 c (shown in FIG. 6B) by an adhesive such as a glue, epoxy, cement, mastic, double-sided tape, cohesive, or any other suitable adhesive. In other aspects, the top seam 156 a can be mechanically attached to the top portion 658 c, such as with a hook-and-loop fastener, staples, or stitching, or other suitable fasteners.

One method for attaching the insulated panel 130 a to the side panel 122 a shown in FIGS. 6A-C can apply to any of the insulated panels 130 a-d, 140 and any of the adjacent panels 112 a,b, 122 a,b,240. The method can also be used to attach the insulated panels 130 a-d to an inner surface, such as inner side surfaces 326 a,b, within the box cavity 206. The method is demonstrated on the assembled box 101, and the method is exemplary and not limiting. The various panels 112 a,b, 122 a,b,306 of the box 101 can also be clad with individual insulated panels 130 a-d prior to assembly of the box 101. For example, the insulated panels 130 a-d, can be attached to the respective panels 112 a,b, 122 a,b of an unfolded box blank 710 (shown in FIG. 7). It can be desirable to attach the insulated panels 130 a-d to the unfolded box blank 710 prior to assembly in order to reduce mechanical handling of the box 101. In another aspect, the insulated box 110 can be formed by wrapping the insulation wrap 1730 around the box 101 as described relative to FIG. 17.

FIG. 7 is a top view of the box blank 710 which can be assembled to form the box 101 of the insulated box 110. The box blank 710 can further define four corner fold lines 750 a-d, such as a scored crease. In other aspects, the box blank 710 can define cuts in place of the corner fold lines 750 a-d. A first corner fold line 750 a can extend outwards from the bottom panel 306 to separate the first wing 312 a from the second wing 324 b. A second corner fold line 750 b can extend outwards from the bottom panel 306 to separate the first wing 312 b from the second wing 324 d. A third corner fold line 750 c can extend outwards from the bottom panel 306 to separate the first wing 312 c from the second wing 324 a. A fourth corner fold line 750 d can extend outwards from the bottom panel 306 to separate the first wing 312 d from the second wing 324 c. In the present aspect, the adjacent wings 312 a-d,324 a-d can be hingedly connected by the corner fold lines 750 a-d. In other aspects, the corner fold lines 750 a-d can be cuts which separate the adjacent wings 312 a-d,324 a-d.

The box blank 710 can define a first length fold line 712 a and a second length fold line 712 b extending from the side panel 112 a to the side panel 112 b. The first length fold line 712 a can facilitate folding of the first wing 312 a relative to the side panel 112 a, the side panel 122 a relative to the bottom panel 306, and the first wing 312 c relative to the second side panel 112 b. The second length fold line 712 b can facilitate folding of the first wing 312 b relative to the side panel 112 a, the side panel 122 b relative to the bottom panel 306, and the first wing 312 d relative to the side panel 112 b.

The box blank 710 can further define a first width fold line 722 a and a second width fold line 722 b. The width fold lines 722 a,b can be defined substantially perpendicular to the length fold lines 712 a,b. The first width fold line 722 a can facilitate folding of the second wing 324 a relative to the side panel 122 a, the side panel 112 b relative to the bottom panel 306, and the second wing 324 c relative to the side panel 122 b. The second width fold line 722 b can facilitate folding of the second wing 324 b relative to the side panel 122 a, the side panel 112 a relative to the bottom panel 306, and the second wing 324 d relative to the side panel 122 b.

The center fold line 382 can extend across and bisect each side panel 112 a,b. The center fold line 382 facilitates each of the side panels 112 a,b folding inwards about the center fold line 382 and towards the bottom panel 306 to facilitate collapsing the insulated box 110 as shown in FIG. 8.

In some aspects, the insulated panels 130 a-d can be attached to the side panels 112 a,b, 122 a,b to the unfolded box blank 710 prior to assembly. In other aspects, a single insulated panel 130 a,b can be attached to the unfolded box blank 710 to cover the side panels 112 a,b, 122 a,b, and in some aspects, the bottom panel 306 as well. In some aspects, the entire unfolded box blank 710 can be covered by a single insulated panel.

FIG. 8 is a perspective view of the insulated box 110 of FIG. 1 in a collapsed configuration. In the present view, the carrying accessory 170 is removed to better show the details of the bottom panel 306. As the insulated box 110 collapses, the side panels 122 a,b (side panels 122 a,b shown in FIG. 1) move inwards together and towards one another, and the side panels 112 a,b fold inwards towards one another (side panels 112 a,b shown in FIG. 1). The V-shaped fold lines 386 a-f (V-shaped fold lines 386 e,f shown in FIG. 7) cooperate to transition the bottom panel 306 from a substantially planar shape to the truncated pyramidal shape. In the truncated pyramidal shape, the center subpanel 380 extends outwards and away from the side panels 112 a,b and the side panels 122 a,b (shown in FIG. 7). Exerting a force upon the center subpanel 380, such as by pushing the box 101 against the ground can cause the insulated box 110 to self-expand into an expanded configuration (shown in FIG. 1) with a substantially rectangular prism shape. The self-expanding action can be desirable to allow for quick and easy reconfiguration of the insulated box 110, unlike many boxes which must be folded and taped together. The insulated boxes 110 can be shipped and stored in the collapsed configuration for space-efficient packing, and a user can simply press upon the center subpanel 380, such as by pressing the center subpanel 380 against the ground, and the insulated box 110 can reconfigure to the expanded configuration.

FIG. 9 is a top view of the carrying accessory 170 of FIG. 1. As previously described, the carrying accessory 170 can be configured to extend beneath the insulated box 110 (shown in FIG. 1) to facilitate hand carrying of the insulated box 110. The carrying accessory 170 can define two pairs of fold lines 910 a,b. A first pair of fold lines 910 a can be defined between the first side portion 172 a and the middle portion 180, and a second pair of fold lines 910 b can be defined between the second side portion 172 b and the middle portion 180. The fold lines of each pair of fold lines 910 a,b can be placed closely together, such as an inch apart or less, and can be substantially parallel to one another. The pairs of fold lines 910 a,b configure the carrying accessory 170 to closely conform to the bottom taper 458 (shown in FIG. 3) of the bottom end 104 of the insulated box 110. The middle portion 180 of the carrying accessory 170 can also define a pair of middle fold lines 912. The middle fold lines 912 can configure the carrying accessory 170 to closely conform to the truncated pyramidal shape of the bottom panel 306 (shown in FIG. 8) when the insulated box 110 is in the collapsed configuration as shown in FIG. 8. In other aspects each or any of the pairs of fold lines 910 a,b and 912 can be substituted with single fold lines as desired.

FIG. 10 is a perspective view of the modular box assembly 100 comprising the insulated box 110 of FIG. 1 and another aspect of a box top 190 in accordance with another aspect of the present disclosure. In the present aspect, the box top 190 can be a tray top 1090. The tray top 1090 can comprise a top panel 1092 and four side panels, as represented by side panels 1094 a,b, extending down from the top panel 1092. The tray top 1090 can be configured to fit over the top end 102 of the box 101 (shown in FIG. 1). The side panels 1094 can fit over the lips 114 a,b, 124 a,b (shown in FIG. 1) to enclose the box cavity 206 (shown in FIG. 2).

FIG. 11 is a perspective view of the modular box assembly 100 comprising the insulated box 110 of FIG. 1 and another aspect of a box top 190 in accordance with another aspect of the present disclosure. In the present aspect, the box top 190 can be a handle panel 1190. The handle top 1190 can comprise a top panel 1192 and a pair of side panels 1196 a,b attached at opposite sides of the top panel 1192. In the present aspect, the top panel 1192 can be positioned between the lips 114 a,b, 124 a,b of the box 101, and the side panels 1196 a,b can be positioned adjacent to the side panels 122 a,b. The side panels 1196 a,b can be hingedly attached to the top panel 1192. The handle top 1190 can further comprise a pair of side tabs 1396 a,b (shown in FIG. 13) which can be attached to the top panel 1192 and which can extend downwards into the box cavity 206 (shown in FIG. 2), adjacent to the side panels 112 a,b. In some aspects, the side tabs of the handle top 1190 can be glued to either the inside or the outside of the side panels 112 a,b to secure the handle top 1190 to the insulated box 110. In other aspects, the handle top 1190 can be secured to the insulated box 110 by tape, banding, a strap, or other restraint mechanism.

A handle loop 1188 a,b can be attached to each side panel 1196 a,b, respectively, by a tape strip 1198 a,b. In the present aspect, the tape strips 1198 a,b can extend completely around the respective side panel 1196 a,b to secure the handle loop 1188 a,b to the side panel 1196 a,b. In the present aspect, the handle loops 1188 a,b can be rope loops. The handle loops 1188 a,b can allow a user to carry the modular box assembly 100. In the present aspect, each handle loop 1188 a,b can comprise a rope, such as a paper rope, a hemp rope, a manila rope, a cotton rope, a flax rope, a plastic rope, or any other suitable type of rope.

In the present aspect, the top panel 1192 can further comprise a pair of folding tabs 1194 a,b. The folding tabs 1194 a,b can cover a pair of hand holes 1195 a,b, respectively. The folding tabs 1194 a,b can be hingedly connected to the top panel 1192, and the folding tabs 1194 a,b can be pressed inwards towards the box cavity 206. With the folding tabs 1194 a,b pressed inwards, a user can put a finger or fingers through each of the hand holes 1195 a,b to pick up the modular box assembly 100. In some aspects, the hand holes 1195 a,b can be positioned close enough together that a user can insert a thumb through a first of the hand holes 1195 a,b and a finger through the second of the hand holes 1195 a,b to pick up the modular box assembly 100 with one hand. In some aspects, the handle top 1190 can comprise the handle loops 1188 a,b but may not comprise the folding tabs 1194 a,b or define the hand holes 1195 a,b. In other aspects, the handle top 1190 can comprise the folding tabs 1194 a,b and define the hand holes 1195 a,b but may not comprise the handle loops 1188 a,b.

FIG. 12 is a perspective view of the modular box assembly 100 comprising the insulated box 110 of FIG. 1 and another aspect of a box top 190 in accordance with another aspect of the present disclosure. The box top 190 can be a zipper top 1290. The zipper top 1290 can comprise a top panel 1292 and a pair of side panels 1294, as represented by the side panel 1294 b. The side panels 1294 can be hingedly attached to the top panel 1292. In the present aspect, the side panels 1294 can overlaps the lips 124 a,b of the side panels 122 a,b of the insulated box 110. The side panels 1294 can be attached to the side panels 122 a,b by an adhesive, such as a glue, mastic, epoxy, cement, double-sided tape, or any other suitable material. In the present aspect, a strip of adhesive (not shown) can be covered by a backing strip (not shown), and the backing strip can be removed to adhere the side panels 1294 to the side panels 122 a,b. The zipper top 1290 can further comprise a pair of tabs (not shown) which can be inserted into the box cavity 206 (shown in FIG. 2) and positioned adjacent to the side panels 112 a,b (side panel 112 b shown in FIG. 1). In other aspects, the tabs can be disposed external to the side panels 112 a,b, similar to the side panels 1294. The tabs can be attached to the side panels 112 a,b by the adhesive or the adhesive strip, and the tabs can seal the box cavity 206.

The top panel 1292 can define a zipper 1280 which can be defined by a perforations extending around the zipper 1280. The zipper 1280 can extend across the top panel 1292 and divide the top panel 1292 into a first top panel portion 1296 a and a second top panel portion 1296 b. The zipper 1280 can be divided into a first zipper portion 1284 a and a second zipper portion 1284 b by a center perforation line 1282. A user can press inwards on the center perforation line 1282 to separate the first zipper portion 1284 a from the second zipper portion 1284 b. Each zipper portion 1284 a,b can then be ripped out of the top panel 1292 along the perforations, thereby detaching the first top panel portion 1296 a from the second top panel portion 1296 b. With the top panel portions 1296 a,b detached, the top panel 1292 can be opened to allow access to contents within the box cavity 206.

FIG. 13 is a top view of another aspect of the handle top 1190 in accordance with another aspect of the present disclosure. In the present aspect, the handle top 1190 may not define the folding tabs 1194 a,b and the hand holes 1195 a,b of the aspect of the handle top 1190 of FIG. 11. The side panel 1196 a can be attached at a first side edge 1394 a of the top panel 1192 by a tape strip 1393 a and a tape strip 2192 a (shown in FIG. 21) attached at opposite sides of the side panel 1196 a and the top panel 1192. An inner edge 1392 a of the side panel 1196 a can be spaced apart from the first side edge 1394 a, and the tape strips 1393 a,2192 a can define a living hinge 1310 a between the side panel 1196 a and the top panel 1192. The side panel 1196 b can be attached at a second side edge 1394 b of the top panel 1192 by a tape strip 1393 b and a tape strip 2192 b (shown in FIG. 21) attached at opposite sides of the side panel 1196 a and the top panel 1192. An inner edge 1392 b of the side panel 1196 b can be spaced apart from the second side edge 1394 b, and the tape strips 1393 b,2192 b can define a living hinge 1310 b between the side panel 1196 b and the top panel 1192.

The living hinges 1310 a,b formed by the tape strips 1393 a,b,2192 a,b can be more flexible than hinges defined into the top panel 1192, such as by a scored crease line. Hinges defined by a scored crease line can demonstrate positional memory which can resist folding completely in half, thereby preventing the side panels 1196 a,b from resting flat against the top panel 1192. With the living hinges 1310 a,b, the side panels 1196 a,b and handle loops 1188 a,b can lie flat on the top panel 1192 which can be desirable for storage or stacking, for example. In other aspects, the side panels 1196 a,b can be attached directly to the top panel 1192 by hinges defined by scored crease lines.

The handle loop 1188 a can define a handle portion 1360 a and two base portions 1362 a,b. The base portions 1362 a,b of the handle loop 1188 a can be laminated to the side panel 1196 a by the tape strips 1393 a, 2192 a, thereby attaching the handle loop 1188 a to the side panel 1196 a. The handle loop 1188 b can define a handle portion 1360 b and two base portions 1362 c,d. The base portions 1362 c,d of the handle loop 1188 b can be laminated to the side panel 1196 b by the tape strips 1393 b, 2192 b, thereby attaching the handle loop 1188 b to the side panel 1196 b.

In other aspects, the base portions 1362 a,b,c,d can be laminated in anchor strips (not shown) which can be laminated to the side panels 1196 a,b by the tape strips 1393 a,b,2192 a,b. The anchor strips can provide increased surface area for the tape strips 1393 a,b,2192 a,b to adhere to. In some aspects, the anchor strip can extend between the respective base portion pairs 1362 a,b and 1362 c,d; however in other aspect, each base portion 1362 a,b,c,d can be laminated in a separate anchor strip.

The side tabs 1396 a,b can be attached to opposite ends of the top panel 1192. The side tab 1396 a can be attached by a hinge 1398 a, and the side tab 1396 b can be attached by a hinge 1398 b. In the present aspect, hinges 1398 a,b can be defined by a scored line which can facilitate folding relative to the top panel 1192. The side tab 1396 a can be inset from the first side edge 1394 a by a side tab shoulder 1395 a and inset from the second side edge 1394 b by a side tab shoulder 1395 d. The side tab 1395 b can be inset from the first side edge 1394 a by a side tab shoulder 1395 b and inset from the second side edge 1394 b by a side tab shoulder 1395 c. The side tabs 1396 a,b can be inset from the side edges 1394 a,b to provide clearance for the side tabs 1396 a,b to fit along the side panels 112 a,b (shown in FIG. 2) and between the shoulders 222 a,b (shown in FIG. 2).

In the present aspect, the handle top 1190 can be uninsulated; however in other aspects, the top panel 1192 can be insulated. For example, in some aspects, the top panel 1192 can comprise the insulated panel 140 (shown in FIG. 1) which can be attached to a top or a bottom surface of the top panel 1192, similar to the box top 190 of FIG. 1.

FIG. 14 is a perspective view of another aspect of the modular box assembly 100 comprising the box 101 of FIG. 1 and the handle top 1190 of FIG. 13. The handle top 1190 can be positioned to cover the box opening 106. In the present aspect, the lips 114 a,b, 124 a,b (lips 124 a,b shown in FIG. 1) can extend upwards from the shoulders 222 a,b (shown in FIG. 3) by a height equal to a thickness of the top panel 1192 such that the top panel 1192 rests flush with the lips 114 a,b, 124 a,b. In other aspects, such as the aspect of FIG. 1, the lips 114 a,b, 124 a,b can extend upwards beyond the top panel 190 (shown in FIG. 1).

Tape strips 1410 a,b can extend from the side panel 112 a, over the top panel 1192, and down the side panel 112 b to secure the top panel 1192 to the box 101. The tape strip 1410 a can be positioned proximate to the side panel 1196 a of the handle top 1190, and the tape strip 1410 b can be positioned proximate to the side panel 1196 b of the handle top 1190 to prevent the side panels 1196 a,b from pulling away from the box opening 106 when the handle loops 1188 a,b are held by a user 1400.

Additionally tape strips 1420, as represented by tape strip 1420 b, can attach the side panels 1196 a,b to the side panels 122 a,b (side panel 122 a shown in FIG. 1). As shown, tape strip 1420 b can define a first portion 1422 a and a second portion 1422 b. The first portion 1422 a of the tape strip 1420 b can be attached to the side panel 122 b, and the second portion 1422 b of the tape strip 1420 b can be attached to the side panel 1196 b to prevent the side panel 1196 b from pulling away from the box opening 106, particularly when the box 101 contains heavy contents. The tape strips 1420 can transfer a load from the handle loops 1188 a,b to the side panels 122 a,b. In other aspects, the handle top 1190 can be secured to the box 101 by a different method or a different arrangement of tape strips 1410 a,b, 1420 b.

FIG. 15 is a perspective view of an inner box 1500, and FIG. 16 is a top view of an inner box blank 1600 of the inner box 1500. The inner box blank 1600 can comprise a center panel 1610, a pair of side flap panels 1618 a,b attached at opposite ends of the center panel 1610, and a first locking panel 1614 and a second locking panel 1616 disposed at opposite ends of the center panel 1610. Each side flap panel 1618 a,b can comprise a side subpanel 1540 a,b respectively attached to the center panel 1610 and a flap subpanel 1640 a,b disposed opposite from the center panel 1610. Each side subpanel 1540 a,b can comprise a side tab 1642 a,b, respectively. Each side tab 1642 a,b can be cut out from the respective flap subpanel 1640 a,b by a side tab cutout 1643 a,b, respectively. Each side tab 1642 a,b can be configured to extend outwards from the flap subpanel 1640 a,b when the side tabs 1642 a,b are folded relative to the flap subpanels 1640 a,b.

The first locking panel 1614 can comprise a side subpanel 1532 a attached to the center panel 1610 and a first locking subpanel 1510 disposed opposite from the center panel 1610. The first locking subpanel 1510 can comprise a pair of wings 1512 a,b, and each wing 1512 a,b can define a locking slot 1514 a,b. The first locking subpanel 1510 can also comprise a channel tab 1530 a which can be cut out from the side subpanel 1532 a. The channel tab 1530 a can be configured to extend outwards from the side subpanel 1532 a when the first locking subpanel 1510 is folded relative to the side subpanel 1532 a.

The second locking panel 1616 can comprise a side subpanel 1532 b attached to the center panel 1610 and a second locking subpanel 1520 disposed opposite from the center panel 1610. The second locking subpanel 1520 can comprise a pair of locking tabs 1522 a,b which can be hingedly attached to the second locking subpanel 1520. A pair of locking notches 1624 a,b can be defined between the second locking subpanel 1520 and the locking tabs 1522 a,b. The second locking subpanel 1520 can also comprise a channel tab 1530 b which can be cut out from the side subpanel 1532 b. The channel tab 1530 b can be configured to extend outwards from the side subpanel 1532 b when the second locking subpanel 1520 is folded relative to the side subpanel 1532 b.

In an assembled configuration shown in FIG. 15, the side subpanels 1532 a,b, 1540 a,b can define four sides of the inner box 1500. The center panel 1610 can define a bottom panel of the inner box 1500. The first locking subpanel 1510 and the second locking subpanel 1520 can overlap to define a top panel of the inner box 1500. The side flap panels 1618 a,b can be folded inwards so that the flap subpanels 1640 a,b lie flat against the first locking subpanel 1510 and the second locking subpanel 1520. The side tabs 1642 a,b can engage the locking slots 1514 a,b of the first locking subpanel 1510 to prevent the side flap panels 1618 a,b from unfolding. Additionally, locking tabs 1522 a,b can extend through the locking slots 1514 a,b and through openings defined by the side tap cutouts 1643 a,b to prevent the side flap panels 1618 a,b from unfolding.

With the locking tabs 1522 a,b extending through the locking slots 1514 a,b, the first locking subpanel 1510 can be secured to the second locking subpanel 1520. The locking notches 1624 a,b can engage the locking slots 1514 a,b to prevent withdrawal of the locking tabs 1522 a,b from the locking slots 1514 a,b. The second locking subpanel 1520 can be positioned overlapping the first locking subpanel 1510, and the locking tabs 1522 a,b can be inserted through the locking slots 1514 a,b to secure the first locking subpanel 1510 to the second locking subpanel 1520.

The inner box 1500 can contain a temperature maintaining material 2110 (shown in FIG. 21) within a cavity 2108 (shown in FIG. 21) of the inner box 1500, and the inner box 1500 can be configured to secure the temperature maintaining material 2110 within the insulated box 110. In some aspects, the inner box 1500 can contain a cooling material, such as carbon dioxide dry ice for example and without limitation, configured to keep contents of the insulated box 110 cold or frozen. In such aspects, as the dry ice sublimes into carbon dioxide gas, the cold carbon dioxide gas can pass downwards from the inner box 1500 through a plurality of vents 1612 defined by the center panel 1610, which can be oriented as the bottom panel. The inner box 1500 can prevent a user from making direct contact with the dry ice by which can cause burns to bare skin. In other aspects, the inner box 1500 can contain a different temperature maintaining material configured to cool the insulated box 110. For example, in some aspects, the temperature maintaining material 2110 can be a mixture of materials configured to undergo a controlled endothermic reaction. For example and without limitation, the temperature maintaining material 2110 can comprise water, ammonium nitrate, calcium ammonium nitrate, and/or urea in a container which can undergo an endothermic reaction as the water dissolves solid material in the container, as commonly used in so-called “instant ice packs”. In such aspects, the temperature maintaining material 2110 can absorb heat through the endothermic reaction.

In other aspects, the temperature maintaining material 2110 can be a heat emitting material configured to keep contents of the insulated box 110 warm or hot. For example and without limitation, the inner box 1500 can contain heat packs which emit residual heat from a heated material defining a high specific heat capacity. For example, a heated water bottle or bag can emit residual heat over time. In other aspects, the inner box 1500 can contain a heat emitting material which can undergo a controlled exothermic reaction to produce heat within the insulated box 110. One example can include a pouch of supersaturated crystallizing solution, such as sodium acetate for example and without limitation, which release heat as crystallization occurs as seen in some hand warmers. Another example can be a mixture which is commonly used in hand warmers which can comprise cellulose, iron, activated carbon, vermiculite, and/or salt which can release heat as oxygen oxidizes the iron as seen in other hand warmers. In such aspects, the temperature maintaining material 2110 can produce heat through the exothermic reaction.

FIG. 17 is a perspective view of another aspect of the insulated box 110 in accordance with another aspect of the present disclosure. In the present aspect, the insulated box 110 can comprise the insulation wrap 1730 configured to wrap or extend around the side panels 112 a,b, 122 a,b of the box 101. In the present aspect, the insulation wrap 1730 may not cover the bottom end 104 of the box 101; however, in other aspects, the insulation wrap 1730 can cover the bottom end 104 as well. The insulation wrap 1730 can comprise an insulation batt 2051 (shown in FIG. 20) which can be thicker than the insulation batt 350 (shown in FIG. 3) of the insulation panels 130 a-d (shown in FIG. 3). In some aspects, the insulation batt 2051 can be 2″ in thickness or greater.

In the present aspect, the insulation wrap 1730 can be defined by one insulated panel 510 (shown in FIG. 5); however, in other aspects, the insulation wrap 1730 can comprise a plurality of insulated panels 510 attached together to encircle the box 101. In other aspects, the insulation wrap 1730 can be formed differently from the insulated panels 510. In the present aspect, opposite ends of the insulation wrap 1730 can be attached together to form a seam 1732 which secures the insulation wrap 1730 around the box 101. In the present aspect, the insulation wrap 1730 can fit snuggly around the box 101, and friction between the insulation wrap 1730 and the box 101 can prevent the insulation wrap 1730 from slipping off of the box 101. In other aspects, the insulation wrap 1730 can be attached to the box 101 through a mechanism such as staples, an adhesive, tape, hook-and-loop fasteners, or any other suitable attachment mechanism.

FIG. 18 is a perspective view of an outer sleeve 1800 of the modular box assembly 100. The outer sleeve 1800 can be configured to fit over the insulated box 110 of FIG. 1, FIG. 17, or any other aspect. With the outer sleeve 1800 fit over the insulated box 110, the insulation wrap 1730 (shown in FIG. 17) or insulated panel 130 a-d (shown in FIG. 3) can be positioned between the box 101 and the outer sleeve 1800. The outer sleeve 1800 can comprise four sides 1812 a,b, 1822 a,b configured to align with the side panels 112 a,b, 122 a,b, respectively. In the present aspect, the side 1822 a can comprise a pair of side subpanels 1824 a,b joined by a seam 1830. In other aspects, the seam 1830 can be positioned at a corner of the outer sleeve 1800.

In the present aspect, the outer sleeve 1800 can comprise a rigid material, such as corrugated cardboard for example and without limitation. The outer sleeve 1800 can provide protection to the insulated box 110, particularly the insulated panels 130 a-d or insulation wrap 1730 of the insulated box 110. In the present aspect, the insulated panels 130 a-d and the insulation wrap 1730 can each comprise sheets of material, such as kraft paper for example and without limitation, and the outer sleeve 1800 can prevent the sheets of material from being damaged or torn during shipping or handling of the modular box assembly 100. The outer sleeve 1800 can also provide substantially flat surfaces which can define graphics or indicia, such as logos, advertisements, decorations, indications of the contents, handling warnings such as “Fragile” or “This Side Up”, or any other indicia for example and without limitation. The outer sleeve 1800 can also provide additional insulation value to the insulated box 110.

FIG. 19 is a perspective view of a support bracket 1910 of the modular box assembly 100 mounted within the box cavity 206 of the box 101. The support bracket 1910 can be configured to support items within the box cavity 206 such as the insulated cavity panel 430, the inner box 1500, the divider panel 2230 (shown in FIG. 22), or any other item, partition, insulation, or barrier. As demonstrated by the shoulder 222 a, each shoulder 222 a,b (shoulder 222 b shown in FIG. 20) can define a shoulder channel 1922 a,b (shoulder channel 1922 b shown in FIG. 20). The shoulder channel 1922 a can be representative of both shoulder channels 1922 a,b. The shoulder channel 1922 a can be defined by the side panel 122 a and the two sub-shoulders 322 a,b of the shoulder 222 a.

The bracket 1910 can comprise a channel tab 1912 and a support shelf 1914, and the channel tab 1912 can be folded to be substantially perpendicular to the support shelf 1914. In the aspect shown, the bracket 1910 can further comprise a brace 1920 which can extend between the support shelf 1914 and the channel tab 1912. The brace 1920 can be folded inward between the channel tab 1912 and the support shelf 1914 to prevent the support shelf 1914 from folding in half towards the channel tab 1912 when a downward load is applied to the support shelf 1914.

The channel tab 1912 can be configured to frictionally engage the sub-shoulders 322 a,b to secure the bracket 1910 within the shoulder channel 1922 a. The channel tab 1912 can define a top end 1916 and a bottom end 1918. The support shelf 1914 can be attached to the channel tab 1912 at the top end 1916 in the present aspect. In some aspects, the channel tab 1912 can taper from the top end 1916 to the bottom end 1918. The taper can ensure that the bottom end 1918 can easily be inserted into the shoulder channel 1922 a while still providing sufficient friction between the sub-shoulders 322 a,b and the channel tab 1912 to secure the channel tab 1912 within the shoulder channel 1922 a.

In the present aspect, the first wings 312 a,c can be substantially flush with the second wings 324 a,b of the sub-shoulders 322 a,b. In other aspects, the first wings 312 a,c can extend further into the support channel 1922 a than the second wings 324 a,b to provide a groove (not shown) between the first wing 312 a, the second wing 324 b, and the side panel 122 a and another groove between the first wing 312 c, the second wing 324 b, and the side panel 122 a. In such aspects, the grooves can capture the channel tab 1912 such that a portion of the channel tab 1912 is positioned between the first wing 312 a and the side panel 122 a and another portion of the channel tab 1912 is positioned between the first wing 312 c and the side panel 122 a. By capturing the channel tab 1912, the grooves can prevent the bracket 1910 from being pulled outwards from the shoulder channel 1922 a in a direction away from the side panel 122 a.

FIG. 20 is a downward cross-section of another aspect of the modular box assembly 100. In the present aspect, the modular box assembly 100 can comprise the insulated box 110 of FIG. 17 which can be nested within the outer sleeve 1800 of FIG. 18. The inner box 1500 of FIG. 15 can be disposed within the box cavity 206 of the box 101 of the insulated box 110. The aspect of FIG. 20 is but one possible combination of elements which demonstrates the modularity and flexibility of the modular box assembly 100.

The insulation wrap 1730 of the insulated box 110 can be positioned between the box 101 and the outer sleeve 1800 in the present aspect. The insulation wrap 1730 can comprise the insulation batt 2051 which can be encapsulated between a first sheet 2052 and a second sheet 2054 of the insulation wrap 1730 by a border 2058. The border 2058 can attach the first sheet 2052 to the second sheet 2054, and the border 2058 can fully enclose the insulation batt 2051. A first border portion 2032 a of the border 2058 can be attached to a second border portion 2032 b of the border 2058 to form the seam 1732 which can secure the insulation wrap 1730 around the box 101. The first border portion 2032 a and the second border portion 2032 b can be defined at opposite ends of the insulation wrap 1730.

In the present aspect, the first sheet 2052 can be in facing contact with the outer sleeve 1800, and the second sheet 2054 can be in facing contact with the box 101. In some aspects, the second sheet 2054 of the second border portion 2032 b can be attached to the box 101, such as with an adhesive, and then the first border portion 2032 a can be attached to the second border portion 2032 b, such as with an adhesive, to secure the insulation wrap 1730 around the box 101.

The inner box 1500 can be sized to fit closely within the box cavity 206. The wings 1512 a,b can contact the side panels 112 a,b. The channel tabs 1530 a,b can extend outwards from the inner box 1500 and into the shoulder channels 1922 a,b. The channel tabs 1530 a,b can be sized and configured to frictionally engage the shoulder channels 1922 a,b to secure and suspend the inner box 1500 within the box cavity 206, as further shown in FIG. 21.

FIG. 21 is a side cross-section of the modular box assembly 100 of FIG. 20, further comprising the handle top 1190 of FIG. 11. As described above, the inner box 1500 can be suspended within the box cavity 206, and the inner box 1500 can divide the box cavity 206 into a first sub-compartment 2106 a and a second sub-compartment 2106 b. In aspects in which the temperature maintaining material 2110 can be a cooling material, such as dry ice, the first sub-compartment 2106 a can contain frozen goods, and the second sub-compartment 2106 b can contain chilled goods. Dense, cold air from the temperature maintaining material 2110 can descend downwards from the temperature maintaining material 2110 through the vent holes 1612 (shown in FIG. 16) into the first sub-compartment 2106 a to maintain a colder temperature in the first sub-compartment 2106 a compared to the second sub-compartment 2106 b.

In aspects in which the temperature maintaining material 2110 can be a heat emitting material, the second sub-compartment 2106 b can maintain a temperature higher than the first sub-compartment 2106 a due to rising hot air from the temperature maintaining material 2110. In such aspects, the inner box 1500 can be turned upside down with the center panel 1610 facing upwards to promote convection through the vent holes 1612 within the second sub-compartment 2106 b. In some aspects, the insulated cavity panel 430 (shown in FIG. 4) can be placed beneath the handle top 1190 to resist heat transfer through the handle top 1190.

As shown, a portion of the first tape strip 1393 a can attach to a portion of the second tape strip 2192 a between the side panel 1196 a and the top panel 1192 to form the living hinge 1310 a of the handle top 1190. A portion of the first tape strip 1393 b can attach to a portion of the second tape strip 2192 b between the side panel 1196 b and the top panel 1192 to form the living hinge 1310 b.

In the present aspect, the modular box assembly 100 can further comprise the bottom insulated panel 2130. The bottom insulated panel 2130 can comprise a sheet 2152, a board 2154, and an insulation batt 2150. In the present aspect, the insulation batt 2150 can be encapsulated and laminated to the board 2154 by the sheet 2152. The sheet 2152 can comprise a thin, flexible material such as a film, a paper, a fabric, a mesh, or any other suitable material. The board 2154 can comprise a rigid material, such as cardboard, a plastic, a metal, a rigid foam, or any other suitable material. The bottom insulated panel 2130 can rest atop the bottom panel 306 of the box 101, and the bottom insulated panel 2130 can provide insulation for the bottom end 104 of the box 101.

The rigidity of the board 2154 can be desirable to prevent collapse of the box 101 or insulated box 110 during shipping or handling of the box 101 or insulated box 110. Collapse of one aspect of the insulated box 110 is demonstrated in FIG. 8. Inadvertent or accidental collapse of the box 101 or insulated box 110 during shipping or handling can crush or damage the contents of the box 101 or insulated box 110. By placing the board 2154 against the bottom panel 306, the rigidity of the board 2154 can prevent folding of the bottom panel 306 along the center fold line 382 (shown in FIG. 7), the corner fold lines 384 a-d (shown in FIG. 7), and the V-shaped fold lines 386 a-f (shown in FIG. 7), thereby preventing collapse of the insulated box 110 or box 101. In some applications, the board 2154, without the insulation batt 2150 and sheet 2152, can be placed atop the bottom panel 306 to prevent collapse as shown in FIG. 22.

FIG. 22 is a side cross-section of another aspect of the modular box assembly 100. In the present aspect, the modular box assembly 100 can comprise the handle top 1190 and the insulated box 110 of FIG. 17 which can be nested within the outer sleeve 1800 of FIG. 18. The modular box assembly 100 can further comprise the support brackets 1910 of FIG. 19 which can engage the shoulder channels 1922 a,b of the box 101. The modular box assembly 100 can further comprise the divider panel 2230 which can be suspended within the box cavity 206 by the support brackets 1910.

The divider panel 2230 can comprise a first sheet 2252, a second sheet 2254, a pair of insulation batts 2250 a,b, and a board 2256. In the present aspect, the board 2256 can be a rigid board; however in other aspects, the board 2256 can be a flexible or resilient board. The board 2256 can be positioned between the insulation batts 2250 a,b, and the board 2256 and the insulation batts 2250 a,b can be encapsulated between the first sheet 2252 and the second sheet 2254. The first sheet 2252 and the second sheet 2254 can be joined by a border 2258 which can extend around the divider panel 2230 to fully enclose the board 2256 and insulation batts 2250 a,b. The divider panel 2230 can divide the box cavity 206 into a first sub-compartment 2206 a and a second sub-compartment 2206 b, and the divider panel 2230 can insulate the first sub-compartment 2206 a from the second sub-compartment 2206 b. The border 2258 can also form a seal with the box 101 to isolate the first sub-compartment 2206 a from the second sub-compartment 2206 b. In other aspects, the divider panel 2230 may not be suspended by the support brackets 1910 but can instead rest upon contents of the first sub-compartment 2206 a, and the compressible nature of the lower insulation batt 2250 b can allow the divider panel 2230 to conform to the contents of the first sub-compartment 2206 a. The divider panel 2230 can provide increased rigidity compared to the insulated cavity panel 430 (shown in FIG. 4) which can be desirable for applications in which the divider panel 2230 supports a load.

In the present aspect, the modular box assembly 100 can further comprise a bag 2200 disposed within the second sub-compartment 2206 b. In other aspects, the bag 2200 can be disposed within the first sub-compartment 2206 a, or the bag 2200 can fill the box cavity 206 in undivided applications. In the present aspect, the bag 2200 can be sealed by a roll top seal 2204 to enclose a bag cavity 2202. In the present aspect, the bag 2200 can comprise a thermally reflective material or radiant barrier, such as a metal foil or a metalized plastic such as mylar, for example and without limitation. The bag 2200 can be configured to maintain higher or lower temperatures within the bag cavity 2202 relative to a temperature within the box cavity 206.

The modular box assembly 100 can further comprise temperature maintaining packs 2208 which can each comprise a temperature maintaining material 2210 enclosed in a container 2212. The temperature maintaining material 2210 can be similar to the temperature maintaining material 2110 (shown in FIG. 21), or the temperature maintaining material 2210 can comprise a different material than the temperature maintaining material 2110. The container 2212 can be a soft container such as a plastic bag, foil pack, fabric sack, or any other suitable soft container, or the container 2212 can be a hard container such as a plastic bottle, metal case, or any other suitable hard container.

The temperature maintaining packs 2208 can be configured to maintain higher or lower temperatures within the box cavity relative to an ambient temperature outside of the box cavity 206. For example, in cooling applications, the temperature maintaining material 2210 can absorb heat through a phase change such as melting ice or subliming dry ice, an endothermic reaction such as dissolving solid solute within a solvent, or warming of a chilled material, heat sink, or cold plate defining a temperature below the ambient temperature. In heating applications, the temperature maintaining material 2210 can release heat through a phase change such as condensation or solidification, an exothermic reaction such as oxidation or solid crystal nucleation in a supersaturated solution, or cooling of a heated material or heat source defining a temperature above the ambient temperature.

The temperature maintaining packs 2208 can be sized and shaped to cover the board 2154 or the bottom panel 306 of the box 101, similar to bricks, to form a first layer. In other aspects, an insulated panel, such as the insulated cavity panel 430 or the bottom insulated panel 2130 can be placed between the temperature maintaining packs 2208 and the bottom panel 306 to reduce heat transfer through the bottom end 104 of the box 101. Contents of the box 101 can be placed atop the temperature maintaining packs 2208, or in some aspects, another layer of temperature maintaining packs 2208 can be placed atop the first layer of temperature maintaining packs 2208 to provide increased heating or cooling time for contents of the box cavity 206. The temperature maintaining packs 2208 can be placed in both or either of the first sub-compartment 2206 a and the second sub-compartment 2206 b or in undivided applications, the temperature maintaining packs 2208 can be placed anywhere within the box cavity 206. In some aspects, the temperature maintaining packs 2208 can be used in the same box cavity 206 with the inner box 1500 and the temperature maintaining material 2110, for example and without limitation, to provide increased heating or cooling time for contents of the box cavity 260.

FIG. 23 is an exploded perspective view of another aspect of the insulated box 110 in accordance with another aspect of the present disclosure. The insulated box 110 of the present aspect can be an internally insulated box. The insulated box 110 can comprise an A-B liner 2310 which can comprise a first liner 2312 a and a second liner 2312 b. The first liner 2312 a and the second liner 2312 b can each be defined by insulated panels 510 which can each be folded into a C-shape.

The first liner 2312 a can define a center panel 2314 a disposed between a first side panel 2316 a and a second side panel 2316 b. A border 158 of the first liner 2312 a can comprise a first end border portion 2320 a defined by the first side panel 2316 a and a second end border portion 2320 b defined by the second side panel 2316 b and disposed opposite from the first end portion 2320 a. A fold 2318 a can be defined between the first side panel 2316 a and the center panel 2314 a, and a fold 2318 b can be defined between the second side panel 2316 b and the center panel 2314 a. A pair of side border portions 2322 a,b of the border 158 can be defined by the side panels 2316 a,b and the center panel 2314 a, and the side border portions 2322 a,b can extend between the respective end border portions 2320 a,b.

The second liner 2312 b can define a center panel 2314 b disposed between a first side panel 2316 c and a second side panel 2316 d. A border 158 of the second liner 2312 b can comprise a first end border portion 2320 c defined by the first side panel 2316 c and a second end border portion 2320 d defined by the second side panel 2316 d and disposed opposite from the first end border portion 2320 c. A fold 2318 c can be defined between the first side panel 2316 c and the center panel 2314 b, and a fold 2318 d can be defined between the second side panel 2316 d and the center panel 2314 b. A pair of side border portions 2322 c,d of the border 158 can be defined by the side panels 2316 c,d and the center panel 2314 b, and the side border portions 2322 c,d can extend between the respective end border portions 2320 c,d.

The liners 2312 a,b can fit together to define a substantially cubic or rectangular prism shape with an inner insulated cavity (not shown) defined by the A-B liner 2310. The end border portions 2320 a,b of the border 158 of the first liner 2312 a can contact the center panel 2314 b of the second liner 2312 b, and the end border portions 2320 c,d of the border 158 of the second liner 2312 b can contact the center panel 2314 a of the first liner 2312 a. The side border portions 2322 c,d of the border 158 of the second liner 2312 b can each extend around the sides of a different one of the side panels 2316 a,b. The side border portions 2322 a,b of the border 158 of the first liner 2312 a can each extend around the sides of a different one of the side panels 2316 c,d.

In the present aspect, the A-B liner 2310 can be oriented so that the center panel 2314 a of the first liner 2312 a covers the box opening 106 of the box 101, the center panel 2314 b of the second liner 2312 b covers the bottom panel 306, and the side panels 2316 a,b,c,d cover the side panels 112 a,b, 122 a,b of the box 101. In the present aspect, the side panels 2316 a,b can cover the side panels 122 a,b, and the side panels 2316 c,d can cover the side panels 112 a,b. In other aspects, the side panels 2316 a,b can cover the side panels 112 a,b, and the side panels 2316 c,d can cover the side panels 122 a,b.

In still other aspects, the A-B liner 2310 can be orientated such that the first side panel 2316 a of the first liner 2312 a covers the box opening 106, and the second side panel 2316 b of the first liner 2312 a covers the bottom panel 306 of the box 101. The side panels 112 a,b, 122 a,b of the box 101 can be covered by the second liner 2312 b and the center panel 2314 a of the first liner 2312 a. Such a configuration can be desirable because the first side panel 2316 a can act as a lid which can be folded about the fold 2318 a to open and close the inner insulated cavity of the A-B Liner 2310 without requiring removal of either of the liners 2312 a,b from the box 101.

In the present aspect, the sheets 352,354,2052,2054,2152,2252,2254 can comprise paper, such as kraft paper; however, in other embodiments, the sheets can comprise posterboard, cardboard, plastic sheeting, cellulose film, cloth, or any other suitable material. In some aspects, the sheets can comprise a water-proof or water-resistant material, such as water-proof paper. In some aspects, a one of the sheets 352,354,2052,2054,2152,2252,2254 of the modular box assembly 100 can comprised a material different from another of the sheets 352,354,2052,2054,2152,2252,2254. In the present aspect, the box 101 can comprise a paper fiber-based material such as corrugated cardboard or poster board; however, the box 101 can comprise any suitable rigid board material such as wood, plastic, metal, or any other material.

The insulation batts 350,2051,2150,2250 a,b can comprise paper or other paper fiber materials; however, in other aspects, the insulation batts can comprise cotton, foam, rubber, plastics, fiberglass, mineral wool, or any other flexible insulation material. In the present application, the insulation batts can be repulpable. In the present aspect, the modular box assembly 100 can be 100% recyclable. In the present aspect, the modular box assembly 100 can be single-stream recyclable wherein all materials comprised by the modular box assembly 100 can be recycled by a single processing train without requiring separation of any materials or components of the modular box assembly 100. In the present aspect, the modular box assembly 100 can be compostable. In the present aspect, the modular box assembly 100 can be repulpable.

In the present aspect, the modular box assembly 100 and each of the insulated box 110, the top panel 190, the insulated panels 130 a-d,430,140,510, the insulation wrap 1730, the bottom insulated panel 2130, the divider panel 2230, and the liners 2312 a,b can be repulpable in accordance with the requirements of the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill. which is hereby incorporated in its entirety. In the present aspect, the modular box assembly 100 and each of the insulated box 110, the top panel 190, the insulated panels 130 a-d,430,140,510, the insulation wrap 1730, the bottom insulated panel 2130, the divider panel 2230, and the liners 2312 a,b can be recyclable in accordance with the requirements of the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill.

Recyclable and repulpable insulation materials are further described in U.S. Provisional Patent Application No. 62/375,555, filed Aug. 16, 2016, U.S. Provisional Patent Application No. 62/419,894, filed Nov. 9, 2016, and U.S. Provisional Patent Application No. 62/437,365, filed Dec. 21, 2016, which are each incorporated by reference in their entirety herein.

Further regarding the manufacture and composition of the insulation batts 350,2051,2150,2250 a,b, one or more of the three above-identified applications, such as U.S. Provisional Patent Application No. 62/375,555, disclose that insulative pads/batts can be manufactured fiber compositions formed by passing recycled cardboard through a mill such as a hammer mill. Optionally, the batts may also be formed from a randomly distributed mixture of reinforcement fibers comprising natural fibers, such as cotton, and binder fibers having a length between 1/16 inch to 1.5 inches and a denier of between 5 and 12. The binder fibers, along with the reinforcement fibers, can be laid randomly yet consistently in x-y-z axes. The reinforcement fibers are generally bound together by heating the binder fibers above their glass transition temperature. As disclosed in U.S. Provisional Patent Applications Nos. 62/419,894 and 62/437,365, what have heretofore been described as reinforcement fibers may also comprise a mixture of recycled cardboard and paper fibers, ranging from and including a 50/50 cardboard/paper mix to and including a 75/25 cardboard/paper mix. The batt material using such reinforcement fibers can comprise 75% cardboard/paper mixture and 25% binder fiber, such batt material having a density of 1600 grams per square meter (“GSM”). Additional materials constructed are 80/20 at 1500 GSM; 80/20 at 1400 GSM; 85/15 at 1600 GSM; 85/15 at 1500 GSM; 85/15 at 1400 GSM; and 90/10 at 1500 GSM, with the first number being the paper/cardboard fiber mixture percentage and second number being a binder fiber percentage (for example, 80/20 is 80% paper/cardboard fiber mixture and 20% binder fiber).

As disclosed in at least U.S. Provisional Patent Application No. 62/375,555, typically, less than about 20% by weight binder fiber is used to form the insulation batts 350,2051,2150,2250 a,b. The binder fibers are preferably thermoplastic fibers selected from the group containing polyethylene, polyester or polypropylene, or mixtures thereof. As further disclosed in U.S. Provisional Patent Applications Nos. 62/419,894 and 62/437,365, the binder fibers may also comprise water soluble and recyclable polyvinyl alcohol (“PVOH”), as well as mixtures of PVOH with any of the aforementioned binder fiber materials. The fiber can be for example a KURALON™ brand short cut fibers. As a binder fiber, the recyclable PVOH fiber used in the insulation can be a 0.4 to 1.0 denier fiber having a length of 3.0-4.0 mm. As still further disclosed in U.S. Provisional Patent Application No. 62/437,365, the binder fiber may be a bi-component fiber comprising polyethylene (“PE”) and polypropylene (“PP”). The PE/PP ratio of this bi-component fiber can range between 50/50 and about 65/35, or it may have the 65/35 PE/PP ratio. Such bi-component fibers may be available under the name ES FIBERVISIONS®, including under product codes EAC, EPS, ESC, ESE, EDC, Herculon T426, and Herculon T457. The binder fibers may also be constructed of recyclable or biodegradable material. The thermoplastic binder fibers may have a weight of less than 0.2 pounds per square foot and, more particularly, preferably about 0.1875 pounds per square foot. The remaining reinforcement fiber may be greater than 0.8 pounds per square foot, and preferably 1.0625 pounds per square foot.

Also as disclosed in at least U.S. Provisional Patent Application No. 62/375,555, the material comprising batts 350,2051,2150,2250 a,b is heated in an oven to a temperature greater than about 350° F. and, more preferably, to a temperature of about 362° F. Such heating causes the binder fibers to melt and couple to the non-binder fibers, thus causing fibers to adhere to each other and solidify during cooling. Upon cooling, the binder fibers solidify and function to couple the non-binder reinforcement fibers together as well as function as reinforcement themselves.

The modular box assembly 100 can be used in applications in which a user or mail carrier transports perishable or temperature-sensitive goods, such as frozen, chilled, or hot goods. For example and without limitation, the modular box assembly 100 can be used to transport groceries, medications, electronics, or any other goods. The modular box assembly 100 can improve upon a common cardboard box by providing insulation to prevent spoilage of the contents. The modular box assembly 100 can also be used to deliver hot goods, such as warm foods.

In order to ship temperature-sensitive goods, common cardboard boxes are often packed with insulating materials made of plastics or foams which are not accepted by many recycling facilities or curb-side recycling programs in which a waste management service collects recyclables at a user's home. Consequently, shipping temperature-sensitive goods often produces non-recyclable waste which is deposited in landfills. The insulation materials often decompose very slowly, sometimes over the course of several centuries. In some instances, non-recyclable and non-biodegradable insulating materials can enter the oceans where the insulation materials can remain for years and harm marine life. In some aspects, the modular box assembly 100 can reduce waste and pollution by comprising materials which are recyclable or biodegradable. In aspects in which the modular box assembly 100 is curb-side or single-stream recyclable, the user may be more likely to recycle the modular box assembly 100 due to the ease of curb-side collection.

One should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular embodiments or that one or more particular embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment.

It should be emphasized that the above-described embodiments are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Any process descriptions or blocks in flow diagrams should be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps in the process, and alternate implementations are included in which functions may not be included or executed at all, may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. 

That which is claimed is:
 1. A modular box assembly comprising: a box, the box comprising a bottom box panel and four side box panels, the four side box panels and the bottom box panel defining a box cavity; a first thermal liner positioned within the box cavity, the first thermal liner comprising a first length of pre-laminated material, the pre-laminated material comprising an insulation batt in facing contact with a first sheet and with a second sheet, the first thermal liner defining three first liner panels, wherein at least one side box panel is covered by a first liner panel; and a second thermal liner positioned within the box cavity, the second thermal liner comprising a second length of the pre-laminated material, the second thermal liner defining three second liner panels, wherein at least one other of the side box panels is covered by a second liner panel; wherein the bottom box panel is covered by one of a first liner panel not covering any side box panel and a second liner panel not covering any side box panel; and wherein the insulation batt is formed from a mixture of reinforcement fibers and thermoplastic binder fibers, the reinforcement fibers comprising one of natural fibers, recycled cardboard, and a mixture of recycled cardboard and paper fibers.
 2. The modular box assembly of claim 1, wherein the pre-laminated material defines at least one unfinished edge along which a portion of the insulation batt is exposed.
 3. The modular box assembly of claim 1, wherein the thermoplastic binder fibers and the reinforcement fibers are randomly distributed.
 4. The modular box assembly of claim 1, wherein the natural fibers comprise cotton.
 5. The modular box assembly of claim 1, wherein a ratio of recycled cardboard to paper fiber in the mixture of recycled cardboard and paper fibers ranges from and including 50/50 to and including 75/25.
 6. The modular box assembly of claim 1, wherein a ratio of reinforcement fibers to binder fibers in the insulation batt is 75/25, and wherein the insulation batt has a density of 1600 GSM.
 7. The modular box assembly of claim 1, wherein a ratio of reinforcement fibers to binder fibers in the insulation batt is 90/10, and wherein the insulation batt has a density of 1500 GSM.
 8. The modular box assembly of claim 1, wherein a ratio of reinforcement fibers to binder fibers in the insulation batt is 80/20.
 9. The modular box assembly of claim 8, wherein the insulation batt has a density of 1500 GSM.
 10. The modular box assembly of claim 8, wherein the insulation batt has a density of 1400 GSM.
 11. The modular box assembly of claim 1, wherein a ratio of reinforcement fibers to binder fibers in the insulation batt is 85/15.
 12. The modular box assembly of claim 11, wherein the insulation batt has a density of 1600 GSM.
 13. The modular box assembly of claim 11, wherein the insulation batt has a density of 1500 GSM.
 14. The modular box assembly of claim 11, wherein the insulation batt has a density of 1400 GSM.
 15. The modular box assembly of claim 1, wherein the thermoplastic binder fibers are composed of at least one of polyethylene, polyester, polypropylene, and polyvinyl alcohol (PVOH).
 16. The modular box assembly of claim 15, wherein the thermoplastic binder fibers composed of PVOH are water soluble and recyclable.
 17. The modular box assembly of claim 1, wherein the thermoplastic binder fibers are biodegradable.
 18. The modular box assembly of claim 1, wherein the modular box assembly is 100% recyclable.
 19. The modular box assembly of claim 1, wherein the first thermal liner and the second thermal liner are each folded into a C-shape.
 20. The modular box assembly of claim 1, wherein the thermoplastic binder fibers each have a length measuring between 1/16 inches and 1.5 inches and a denier of between 5 and
 12. 21. The modular box assembly of claim 1, wherein the insulation batt comprises less than about 20% by weight of thermoplastic binder fibers.
 22. The modular box assembly of claim 21, wherein the thermoplastic binder fibers have a weight of about 0.1875 pounds per square foot.
 23. The modular box assembly of claim 1, wherein the reinforcement fibers exceed 0.8 pounds per square foot.
 24. The modular box assembly of claim 23, wherein the reinforcement fibers weigh 1.0625 pounds per square foot.
 25. The modular box assembly of claim 1, wherein the first sheet and the second sheet comprise one of paper, posterboard, cardboard, plastic sheeting, cellulose film, and cloth.
 26. The modular box assembly of claim 25, wherein the first sheet and the second sheet comprise paper, wherein the reinforcement fibers in the insulation batt are composed of at least one of recycled cardboard and paper fibers, and wherein the pre-laminated material is pre-laminated paper.
 27. A method of manufacturing a modular box assembly, comprising the steps of: constructing an insulation batt by combining thermoplastic binder fibers and reinforcement fibers to result in a fibrous web, heating the fibrous web to a temperature exceeding a glass transition temperature of the thermoplastic binder fibers, resulting in melting of the thermoplastic binder fibers, and cooling the fibrous web, the cooling causing the thermoplastic binder fibers to solidify and to couple reinforcement fibers together; constructing pre-laminated material by attaching a first sheet in facing contact with the insulation batt, and attaching a second sheet in facing contact with the insulation batt opposite the first sheet; cutting the pre-laminated material to size to define a first laminated member; cutting the pre-laminated material to size to define a second laminated member; folding portions of the first laminated member to form a first thermal liner; folding portions of the second laminated member to form a second thermal liner; positioning the first thermal liner in a box cavity defined by a box; and positioning the second thermal liner in the box cavity such that the first thermal liner and the second thermal liner together form an insulated cavity within the box cavity.
 28. The method of claim 27, wherein the first sheet and the second sheet comprise one of paper, posterboard, cardboard, plastic sheeting, cellulose film, and cloth.
 29. The method of claim 28, wherein the first sheet and the second sheet comprise paper, wherein the reinforcement fibers in the insulation batt are composed of at least one of recycled cardboard and paper fibers, and wherein the pre-laminated material is pre-laminated paper.
 30. The method of claim 29, further comprising the step of dispensing the pre-laminated paper from a roll.
 31. The method of claim 27, wherein the temperature exceeds 350° F.
 32. The method of claim 31, wherein the temperature is about 362° F.
 33. The method of claim 27, wherein the thermoplastic binder fibers are biodegradable.
 34. The method of claim 27, wherein the thermoplastic binder fibers are composed of at least one of polyethylene, polyester, polypropylene, and polyvinyl alcohol (PVOH).
 35. The method of claim 34, wherein the thermoplastic binder fibers composed of PVOH are water soluble and recyclable.
 36. The method of claim 27, wherein the box comprises a bottom box panel and four side box panels; wherein the step of positioning the first thermal liner in the box cavity comprises the step of covering at least one of the side box panels with a first liner panel; and wherein the step of positioning the second thermal liner in the box cavity comprises the step of covering at least one other of the side box panels with a second liner panel.
 37. The method of claim 36, further comprising the step of covering the bottom box panel with one of a first liner panel not covering any side box panel and a second liner panel not covering any side box panel. 